Clamp Assembly

ABSTRACT

A clamp assembly for solar panels comprising a base and a clamp. The base has a baseplate and first and second spaced-apart struts connected to the baseplate to form a channel. Surfaces of the struts define slots adjacent to the channel. Beams are connected to the struts, and spacers are attached to the beams. Each spacer has an angled surface adjacent to the channel and a curved surface. The clamp includes a plate with fingers extending from the plate into the channel. The clamp further includes angled surfaces in contact with the spacer angled surfaces. Bolts extend through the plate so that most of the threaded portions are positioned between fingers. Corresponding nuts are positioned in the slots and inhibited from rotation during threading with the bolt by the slot surfaces. The clamp assembly is preferably made from a nonconductive material to inhibit arcing and the risk of electrical fire from incorrect or failed wiring.

CROSS-REFERENCES TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

With the continual rise in conventional energy costs, solar panels arebecoming more popular in residential settings. Typically, residentialsystems involve the use of a number of solar panels interconnected andmounted to a rooftop, and can cover many thousands of square feet.Because typical systems operate at above 400 VDC, residential codesoften require that each panel of the system, as well as the mountingequipment, be grounded.

Such arrays require a sufficiently strong mounting system to support notonly the weight of the array, but to also provide sufficient resistanceto wind forces. Tightly spaced panels effectively form a large surfacearea, which could result in damage to the panels, the mounting system,or both, under strong wind conditions. In addition, these systems mustaccommodate a range of surface types and conditions, including grassyfields, bare earth, cement slabs, and gravel or crushed rock.

Most panels are formed with an aluminum frame around the panel, withmounting holes in the aluminum frame on the back of the panel. Theactual dimensions of the panels vary from manufacturer to manufacturer.Some panels are rectangular, while others have a more-square aspectratio. As a result, the location of the mounting holes varies dependingon the manufacturer and the specific product. Thus, the designer of themounting structure must also first know the exact model of panel to beused in order to design an appropriate mounting structure.

For mounting hardware manufacturers, this may require the design of manydifferent mounting brackets, increasing the costs associated withtooling and inventory control. Alternatively, some support structureconfigurations use special “clips” to clip the solar panels ontosupporting rails. The clips slide onto the rail and are positioned inbetween the panels to secure the edges of the panels to the supportrail. This, however, requires that the clips be slid onto the rail fromthe ends of the rail. If a panel is defective and/or damaged and needsto be replaced, it is difficult to only remove a single panel. This typeof mounting system also often requires extensive on-site placement,measurement, and adjustment on the part of the system installers.Moreover, these clips do not utilize the manufacturers' mounting holes,and therefore the installations may not meet the manufacturers'installation guidelines and/or invalidate warranties. Finally,conventional mounting systems require a large number of components,which increases the dollar value of inventory that must be carried by aninstaller in order to be prepared for any specific installation.

BRIEF SUMMARY OF THE INVENTION

The present invention is a clamp assembly for use in a solar panelmounting system for attaching one or more solar panels to a rooftop. Thepresent invention is estimated to reduce rooftop labor by an installerby approximately eighty percent compared to conventional systems. Thepresent invention also eliminates the need for mechanical bonding(grounding), which reduces the risk of fire and electrocution hazards.In addition, the present invention reduces the inventory of parts thatmust be carried by an installer by a factor of at least fifty.

The present invention comprises a base and a clamp. The base has abaseplate and first and second spaced-apart struts connected to thebaseplate to form a channel. Surfaces of the struts define slotsadjacent to the channel. Beams are connected to the struts, and spacersare attached to the beams. Each spacer has an angled surface adjacent tothe channel and a curved surface. The clamp includes a plate withfingers extending from the plate into the channel. The clamp furtherincludes angled surfaces in contact with the spacer angled surfaces.Bolts extend through the plate so that most of the threaded portions arepositioned between fingers. Corresponding nuts are positioned in theslots and inhibited from rotation during threading with the bolt by theslot surfaces. The clamp assembly is preferably made from anonconductive material to inhibit arcing and the risk of electrical firefrom incorrect or failed wiring.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an assembly view of a first embodiment of the invention.

FIG. 2 is a side elevation from line 2-2 of FIG. 1.

FIG. 3 is a sectional view along line 3-3 of FIG. 2.

FIG. 4 is a side elevation from line 4-4 of FIG. 1.

FIG. 5 is a sectional view along 5-5 of FIG. 4.

FIG. 6 is a side elevation from line 6-6 of FIG. 1.

FIG. 7 is a side elevation from line 7-7 of FIG. 6.

FIG. 8 is an isometric view of the first embodiment.

FIG. 9 is a side elevation from line 9-9 of FIG. 8.

FIG. 10 is a sectional view along line 10-10 of FIG. 9.

FIG. 11 is an isometric view of a second embodiment.

FIG. 12 is a side elevation from line 12-12 of FIG. 11.

DETAILED DESCRIPTION OF THE VARIOUS EMBODIMENTS

Referring to FIG. 1, a first embodiment 20 of the present inventioncomprises a base 22 and a clamp 24. The base 22 and clamp 24 are madefrom a nonconductive material, such as fiberglass-nylon composite.Preferably, composite is a glass fiber reinforced residence, such asZYTEL® 70G33L manufactured by DuPont Company.

The base 22 has a baseplate 26, a first strut 28, and a second strut 30.Both the first strut 28 and the second strut 30 are connected to (e.g.,attached to, integrally formed with, etc.) the baseplate 26. The firststrut 28 is spaced a distance from the second strut 30 to form a channel32 having a U-shaped profile with an open end to receive the clamp 24.The channel 32 extends between ends of the base 22. The baseplate 26includes cylindrical surfaces 38 defining holes for receiving fasteners,such as decking screws 40.

The base 22 further includes a first beam 42 and a second beam 44. Thefirst beam 42 is connected to the first strut 28 opposite the baseplate26. The first beam 42 includes a first beam surface 46. The second beam44 is connected to the second strut 30 opposite the baseplate 26 andopposite the channel 32 from the first beam 42. The second beam 44includes a second beam surface 48 coplanar with the first planar surface46.

A first spacer 50 and a second spacer 52 are attached to the beams 42,44. The first spacer 50 is connected to the first beam 42 at the firstbeam surface 46 adjacent to the open end of the channel 32. The secondspacer 52 is connected to the second beam 44 at the second beam surface48 adjacent to the open end of the channel 32.

Referring to FIG. 2, the first spacer 50 has a planar first spacersurface 54 angled at an angle α relative to the first beam surface 46and a planar second spacer surface 56 parallel to the first planarsurface 46. The first spacer 50 further includes a curved third spacersurface 58 adjacent to the first and second spacer surfaces 54, 56. Theangle A is forty-five degrees.

The second spacer 52 has a planar fourth spacer surface 62 angled atangle A relative to the second beam surface 48, and a planar fifthspacer surface 60 parallel to the second beam surface 48 and coplanarwith the second spacer surface 56. The second spacer 52 further includesa curved sixth spacer surface 64 adjacent to the fourth spacer surface62 and fifth spacer surfaces 60.

Referring jointly to FIG. 2-3, a tie 66 occupies the channel 32 and isconnected to the first strut 28 and the second strut 30. The first strut28 includes a first planar surface 68 and the second strut 30 includes asecond planar surface 70 opposite the first planar surface 68 and spaceda first distance D1 apart. The first strut 28 includes a first slotdefined by a first slot endwall 76 adjacent and perpendicular to thefirst planar surface 68 and first slot sidewalls 78 adjacent andperpendicular to the endwall 76. The second strut 30 includes a secondslot defined by a second slot endwall 80 adjacent and perpendicular tothe second planar surface 70 and second slot sidewalls 82 adjacent andperpendicular to the second slot endwall 80. The first slot and secondslot mirror one another and across a midplane of the base.

Referring jointly to FIG. 4-5, the first strut 28 includes a third slotdefined by a third slot endwall 81 adjacent and perpendicular to thefirst planer surface 68 and third slot sidewalls 83 adjacent andperpendicular to the third slot endwall 81. The second strut 30 includesa fourth slot defined by a fourth slot endwall 85 adjacent andperpendicular to the second planar surface 70 and fourth slot sidewalls87 adjacent and perpendicular to the fourth slot endwall 85. The thirdslot and fourth slot mirror of one another and across the midplane ofthe base.

Referring to FIG. 6, the clamp 24 includes a plate 84 having a planarfirst clamp surface 86, a planar second clamp surface 88 parallel to thefirst clamp surface 86, and a planar third clamp surface 90 coplanarwith the second clamp surface 88. A planar fourth clamp surface 92 isadjacent to the second clamp surface 88 and angled at angle B, where Bequals ninety degrees plus A, relative to the second clamp surface 88. Aplanar fifth clamp surface 94 is adjacent to the third clamp surface 90and angled at an angle B relative to the third planar surface 90. Afirst finger 96 extends away from the plate 84 and has a width less thanD1.

Referring to FIG. 7, the first finger 96, a second finger 98, a thirdfinger 100, and a fourth finger 102 extend away from the plate 84, witheach finger being of the same width. Each finger is a rectangular cuboidwith a first end proximal to the top plate 84 and an opposing end distalfrom the top plate 84. The fifth clamp surface 94 is adjacent to theproximal ends of the fingers. The distance between the first finger 96and the second finger 98 is D2. The distance between the third finger100 and the fourth finger 102 is D2. The distance between the secondfinger 98 and the third finger 100 is equal to D3, which is less thanD2. In alternative embodiments, the distance between the first finger 96and the second finger 98 may be different than the distances between thethird finger 100 and the fourth finger 102.

The clamp 24 further includes two cylindrical surfaces 104, 106 thatdefine holes having axes 108, 110 opening between the first clampsurface 86 and a planar seventh surface 112 and a planar eighth surface114, respectively. The seventh surface 112 is adjacent to and betweenthe proximal ends of the first finger 96 and the second finger 98. Thefirst axis 108 is aligned with the space between the first and secondfingers 96, 98. The second axis 110 is aligned with the space betweenthe third and fourth fingers 100, 102. A planar ninth clamp surface 116is adjacent to and between the proximal ends of the second finger 98 andthe third finger 100.

Referring to FIGS. 8-10, the clamp 24 is attached to the base 22 with abolt 122. Referring specifically to FIG. 10, the bolt 122 extends to aposition within the channel 32 and between the third and fourth fingers100, 102. A second nut 126 has a width-across-flats F greater than thechannel width D1, but slightly less than D2 (see FIGS. 2, 4). The nut126 is positioned in the second and fourth slots and threadedly engagedwith the bolt 122. The first slot extends from one end of the base 22 adistance greater than the width of the first finger 96 but less than thesum of the width of the first finger 96 and D2. In other words, thefirst slot endwall 76 is longitudinally positioned between the firstfinger 96 and the second finger 98. The third slot extends from theother end of the base 22 the same distance, although in alternativeembodiments, the slots may extend from ends of the base 22 separatedistances.

Installation of the embodiment 20 is described with reference to FIG. 1.To install the embodiment 20, four decking screws 40 are positionedthrough the holes in the baseplate 26 to fix the base 22 to the roofing.The first nut 124 is placed in the channel 32 in the first slot and thesecond slot and moved (e.g., pushed with a screwdriver or other tool) tocontact the first and second slot endwalls 76, 80. In this position, thefirst nut 124 is aligned with the first axis 108 when the clamp isinstalled. The second nut 126 is placed in the third slot and fourthslot and moved to the third and fourth slot endwalls 81, 85. Thereafter,the clamp 24 may be positioned relative to the base 22 by inserting thefingers 96, 98, 100, 102 into the channel 32. When the first nut 124 ispositioned against the first and second slot endwall 76, 80, the firstand second fingers 96, 98 will not be obstructed by the first nut 124during insertion of the clamp 24. When the second nut 126 is positionedagainst the third and fourth slot endwalls 81, 85, the third and fourthfingers 100, 102 will not be obstructed by the second nut 126 duringinsertion. The space between the second finger 98 and third finger 100is only slightly larger than the tie 66, which promotes proper alignmentof the clamp 24 with the base 22 during insertion. Thereafter, bolts120, 122 may be disposed through the holes and thread to the nuts 124,126. Rotation of the nuts 124, 126 during threading of the bolts 120,122 is inhibited by the respective slot surfaces. Although nuts 124, 126are shown as hex nuts, other types of fasteners may also be used, suchas square nuts.

Referring to FIG. 9, when properly installed, the angled surfaces 92, 94of the clamp 24 are in contact with angled surfaces 54, 62,respectively, of the base 22. The second and third surfaces 88, 90 ofthe clamp 24 are in contact with the planar surfaces 56, 60. Thereafter,a solar panel may be partially positioned between the clamp 24 and thefirst beam 42. A second solar panel may be partially positioned betweenthe clamp 24 and the second beam 44. The curved surfaces 58, 64 of thespacers 50, 52 are in contact with the panels and enables adjustment ofpanel placement.

Referring to FIGS. 11-12, an alternative embodiment 200 teaches a thirdcylindrical surface 202 defining a third hole through the clamp plate 84and a cylindrical surface 204 defining a hole through the second beam44. When the embodiment 200 is only used with a single solar panel, thepanel is positioned between the first beam 42 and the clamp 24. A bolt206 fastens the clamp 24 to the base 22 with a third nut 208 to inhibitmovement of the clamp 24 due to the lack of a load opposite the singlesolar panel.

The present invention is described in terms of a preferred and otherspecifically-described embodiments. Those skilled in the art willrecognize that alternative embodiments of such device can be used incarrying out the present invention. Other aspects and advantages of thepresent invention may be obtained from a study of this disclosure andthe drawings, along with the appended claims.

1. A solar panel clamp assembly comprising: a base comprising: abaseplate; a first strut connected to said baseplate, said first struthaving a first plurality of surfaces defining a first slot having anfirst slot endwall and a second slot having a second slot endwall; asecond strut connected to said baseplate and spaced a first distancefrom said first strut forming a channel adjacent to said first slot andsaid second slot, said second strut including a third plurality of slotsurface surfaces defining a third slot having a third slot endwall and afourth plurality of slot surfaces defining a fourth slot endwall; afirst beam connected to the first strut opposite the baseplate, saidfirst beam including a first beam surface; and a second beam connectedto the second strut opposite the baseplate and opposite the channel fromthe first beam, said second beam including a second beam surfacecoplanar with said first beam surface; a clamp comprising: a platehaving a first clamp surface, a second clamp surface parallel to saidfirst clamp surface, a third clamp surface coplanar with said secondclamp surface, a first cylindrical surface defining a hole having afirst axis, and a second cylindrical surface defining a hole having asecond axis; a fourth clamp surface adjacent to the second clamp surfaceand angled at a second angle relative to said second clamp surface; afifth clamp surface adjacent to the third clamp surface and angled at asaid second angle relative to said third clamp surface; a first fingerand a second finger adjacent to said fourth clamp surface and said fifthclamp surface, said second finger spaced a second distance from saidfirst finger, said first axis intersecting the space between said firstfinger and said second finger; and a third finger and a fourth fingeradjacent to said fourth clamp surface and said fifth clamp surface, saidfourth finger spaced said second distance from said third finger, saidthird finger spaced a third distance from said second finger, and saidsecond axis intersecting the space between said third finger and saidfourth finger.
 2. The clamp assembly of claim 1 wherein said basefurther comprises: a first spacer connected to said first beam surface,said first spacer having a first spacer surface adjacent to said channeland angled at a first angle relative to said first beam surface; and asecond spacer connected to said second beam surface, said second spacerhaving a second spacer surface adjacent to said channel opposite saidfirst spacer surface and angled at said first angle relative to saidsecond beam surface.
 3. The clamp assembly of claim 2 wherein saidsecond angle equals said first angle plus ninety degrees.
 4. The clampassembly of claim 1 further comprising a tie partially occupying saidchannel, said tie connected to said first strut and said second strut.5. The clamp assembly of claim 1 wherein said base and said clamp aremade from a nonconductive material.
 6. The clamp assembly of claim 1wherein said first slot endwall and said third slot endwall arepositioned adjacent to the space between said first finger and saidsecond finger, and wherein said third slot endwall and said fourth slotendwall are positioned adjacent to the space between said third fingerand said second finger.
 7. A base for a solar panel clamp assembly, thebase comprising: a baseplate; a first strut connected to said baseplate,said first strut having a first plurality of surfaces defining a firstslot having an first slot endwall and a second slot having a second slotendwall; a second strut connected to said baseplate and spaced a firstdistance from said first strut forming a channel adjacent to said firstslot and said second slot, said second strut including a third pluralityof slot surface surfaces defining a third slot having a third slotendwall and a fourth plurality of slot surfaces defining a fourth slotendwall; a first beam connected to the first strut opposite thebaseplate, said first beam including a first beam surface; and a secondbeam connected to the second strut opposite the baseplate and oppositethe channel from the first beam, said second beam including a secondbeam surface coplanar with said first beam surface;
 8. The base of claim7 further comprising: a first spacer connected to said first beamsurface, said first spacer having a first spacer surface adjacent tosaid channel and angled at a first angle relative to said first beamsurface; and a second spacer connected to said second beam surface, saidsecond spacer having a second spacer surface adjacent to said channelopposite said first spacer surface and angled at said first anglerelative to said second beam surface.
 9. The base of claim 8 whereinsaid second angle equals said first angle plus ninety degrees.
 10. Thebase of claim 7 further comprising a tie partially occupying saidchannel, said tie connected to said first strut and said second strut.11. A clamp for a solar panel assembly, the clamp comprising: a platehaving a first clamp surface, a second clamp surface parallel to saidfirst clamp surface, a third clamp surface coplanar with said secondclamp surface, a first cylindrical surface defining a hole having afirst axis, and a second cylindrical surface defining a hole having asecond axis; a fourth clamp surface adjacent to the second clamp surfaceand angled at a second angle relative to said second clamp surface; afifth clamp surface adjacent to the third clamp surface and angled at asaid second angle relative to said third clamp surface; a first fingerand a second finger adjacent to said fourth clamp surface and said fifthclamp surface, said second finger spaced a second distance from saidfirst finger, said first axis intersecting the space between said firstfinger and said second finger; and a third finger and a fourth fingeradjacent to said fourth clamp surface and said fifth clamp surface, saidfourth finger spaced said second distance from said third finger, saidthird finger spaced a third distance from said second finger, and saidsecond axis intersecting the space between said third finger and saidfourth finger.